Potential of using a single fermenter for biomass build-up,starch hydrolysis,and ethanol production

Data on conversion of starch on biomass and ethanol bySchwanniomyces castellii in an aerobic-anaerobic solid state fermentation is reported.Schwanniomyces castellii grew exponentially in the aerobic phase (12 h) and simultaneously hydrolyzed nearly half (55%) of the starch initially present. The accumulation of glucose increased up to 12 h, whereas maltose was nearly absent beyond 7 h. Shift of metabolism from oxidative to fermentative pattern was observed about 10 h as a result of the build-up of CO₂ level and faster utilization of O₂. The ethanol production in the anaerobic phase reached the level of 89.3 mg ethanol/g initial dry matter by the end of 30 h. A total of 92.9% of the starch is utilized during the fermentation. The overall ethanol conversion yields are 57.8% of the theoretical value, whereas in the anaerobic phase it was found to be 94.4%. The cell shape, its morphology, and the type of attachment to the solid support were found to be similar in aerobic and anaerobic phases of fermentation. Data given in this work indicate the feasibility of using one single fermenter for aerobic growth to generate inoculum as well as to simultaneously hydrolyze the starch and subsequent anaerobic fermentation to produce ethanol.     

Production of α-amylase with Aspergillus oryzae on spent brewing grain by solid substrate fermentation

Ten Aspergillus oryzae strains were screened in solid substrate fermentation for α-amylase production on spent brewing grain (SBG) and on corn fiber. SBG proved to be a better substrate for enzyme production than corn fiber. A Plackett-Burman experimental design was used to optimize the medium composition for the best strain. Solid substrate fermentation on optimized medium with A. oryzae NRRL 1808 (=ATCC 12892) strain in stationary 500-mL Erlenmeyer flask culture yielded 4519 U of α-amylase/g of dry matter substrate in 3 d. The whole solid substrate fermentation material (crude enzyme, in situ enzyme) may be considered a cheap biocatalytic material for animal feed rations and for bioalcohol production from starchy materials.     

Scale-up of microbubble dispersion generator for aerobic fermentation

A laboratory-scale microbubble dispersion (MBD) generator was shown to improve oxygen transfer to aerobic microorganisms when coupled to the conventional air-sparger. However, the process was not demonstrated on a large scale to prove its practical application. We investigated the scale-up of a spinning-disk MBD generator for the aerobic fermentation of Saccharomyces cerevisiae (baker’s yeast). A 1-L spinning-disk MBD generator was used to supply air for 1- and 50-L working volume fermentation of baker’s yeast. For the two levels investigated, the MBD generator maintained an adequate supply of surfactant-stabilized air microbubbles to the microorganisms at a relatively low agitation rate (150 rpm). There was a significant improvement in oxygen transfer to the microorganism relative to the conventional sparger. The volumetric mass transfer coefficient, k _L a, for the MBD system at 150 rpm was 765 h⁻¹ compared to 937 h⁻¹ for the conventional sparger at 500 rpm. It is plausible to surmise that fermentation using larger working volumes may further improve the k _L a values and the dissolved oxygen (DO) levels because of longer hold-up times and, consequently, improve cell growth. There was no statistically significant difference between the cell mass yield on substrate (0.43 g/g) under the MBD regime at an agitation rate of 150 rpm and that achieved for the conventional air-sparged system (0.53 g/g) at an agitation rate of 500 rpm. The total power consumption per unit volume of broth in the 50-L conventional air-sparged system was threefold that for the MBD unit for a similar product yield. Practical application of the MBD technology can be expected to reduce power consumption and therefore operating costs for aerobic fermentation.     

Solid state fermentation of plant residues for improved animal feed byPleurotus sp.

In laboratory-scale experiments, studies were made on the solid state fermentation of plant residues—rice straw and the upper soft portion of the stems of sarkanda (Saccharum munja)—by selected cultures of white-rot fungi,Pleurotus sajor-caju andPleurotus ostreatus. These cultures were selected after preliminary screening of their lignin-degrading capacities on lignin-agar medium. Their lignin degrading and (cellulose + hemicellulose) sparing, along with protein improving capacities, were studied for their potential application in animal feed production. A 100 g quantity of presoaked and sterilized residues was inoculated with wheat spawn of the two cultures and incubated at 25‡C. It was observed that, after 25 d, the crude protein contents (N × 6.25) of rice straw increased from 3 to 17.0% in the case of P.sajor-caju and to 19.2% in case of P. ostreatus. The percent removal values of cellulose, hemicellulose, and lignin were found to be as follows: 45.8, 16.8, and 47.1%, respectively, in the case ofP. sajor-caju and 56.5, 40.4, and 50%, respectively, in the case of P.ostreatus. After solid state fermentation of sarkanda for 25 d, its protein content increased from 3 to 12.8% in the case ofP. sajor-caju and to 14.5% in the case ofP. ostreatus. The percent removal of cellulose, hemicellulose, and lignin was found to be as follows: 31.2, 7.1, and 19%, respectively, in the case ofP. sajor-caju and 34.4, 7.1, and 14.3%, respectively, in the case ofP. ostreatus. The results obtained after solid state fermentation of the two residues by the mixed culture of these two basidiomycetes was also presented.     

Effect of media composition and growth conditions on production of β-glucosidase by Aspergillus niger C-6

The hydrolytic activity of fungal originated β-glucosidase is exploited in several biotechnological processes to increase the rate and extent of saccharification of several cellulosic materials by hydrolyzing the cellobiose which inhibits cellulases. In a previous presentation, we reported the screening and liquid fermentation with Aspergillus niger, strain C-6 for β-glucosidase production at shake flask cultures in a basal culture medium with mineral salts, corn syrup liquor, and different waste lignocellulosic materials as the sole carbon source obtaining the maximum enzymatic activity after 5–6 d of 8.5 IU/mL using native sugar cane bagasse. In this work we describe the evaluation of fermentation conditions: growth temperature, medium composition, and pH, also the agitation and aeration effects for β-glucosidase production under submerged culture using a culture media with corn syrup liquor (CSL) and native sugar cane bagasse pith as the sole carbon source in a laboratory fermenter. The maximum enzyme titer of 7.2 IU/mL was obtained within 3 d of fermentation. This indicates that β-glucosidase productivity by Aspergillus niger C-6 is function of culture conditions, principally temperature, pH, culture medium conditions, and the oxygen supply given in the bioreactor. Results obtained suggest that this strain is a potential microorganism that can reach a major level of enzyme production and also for enzyme characterization.     

Variable Volume Fed-Batch Fermentation for Nisin Production by <Emphasis Type="Italic">Lactococcus lactis</Emphasis> subsp<Emphasis Type="Italic">. lactis W28</Emphasis>

A feeding technology that was suitable for improving the nisin production by Lactococcus lactis subsp. lactis W28 was established. The effects of initial sucrose concentration (ISC) in the fermentation broth, feeding time, and feeding rate on the fermentation were studied. It was observed that a fed-batch culture (ISC = 10 g l⁻¹) with 100 ml sucrose solution (190 g l⁻¹) being evenly fed (9–10 ml h⁻¹) into the fermenter after 3-h fermentation gave the best performance in terms of biomass and nisin yield. Under these conditions, the total biomass and the total nisin yield were approximately 23% and 51% higher than those in batch fermentation, respectively. When the sucrose concentration was controlled at 5–10 g l⁻¹ in variable volume intermittent fed-batch fermentation (VVIF) with ISC = 10 g l⁻¹, the total biomass and the total nisin yield were 29% and 60% above those in batch fermentation, respectively. The VVIF proved to be effective to eliminate the substrate inhibition by maintaining sucrose at appropriate levels. It is also easy to be scaled up, since various parameters involved in industrial production were taken into account.     

Production of Raw Starch-Saccharifying Thermostable and Neutral Glucoamylase by the Thermophilic Mold <Emphasis Type="Italic">Thermomucor indicae-seudaticae</Emphasis> in Submerged Fermentation

Among physical and nutritional parameters optimized by “one variable at a time” approach, four cultural variables (sucrose, MgSO₄ ^.7H₂O, inoculum size, and incubation period) significantly affected glucoamylase production. These variables were, therefore, selected for optimization using response surface methodology. The p-values of the coefficients for linear effect of sucrose and inoculum size were less than 0.0001, suggesting them to be the key experimental variables in glucoamylase production. The enzyme production (34 U/ml) attained under optimized conditions (sucrose, 2%; MgSO₄ ^.7H₂O, 0.13%; yeast extract, 0.1%; inoculum size, 5 × 10⁶ spores per 50 ml production medium; incubation time, 48 h; temperature, 40°C; and pH 7.0) was comparable with the value predicted by polynomial model (34.2 U/ml). An over all 3.1-fold higher enzyme titers were attained due to response surface optimization. The experimental model was validated by carrying out glucoamylase production in shake flasks of increasing capacity (0.25–2.0 l) and 22-l laboratory bioreactors (stirred tank and airlift), where the enzyme production was sustainable. Furthermore, the fermentation time was reduced from 48 h in shake flasks to 32 h in bioreactors.     

Significant Improvement of <Emphasis Type="Italic">Serratia marcescens</Emphasis> Lipase Fermentation,by Optimizing Medium,Induction, and Oxygen Supply

Production of an extracellular lipase from Serratia marcescens ECU1010, which is an industrially important biocatalyst for the stereospecific synthesis of Diltiazem precusor, was carefully optimized in both shake flasks and a fermenter, using Tween-80 as the enzyme inducer. Dextrin and beef extract combined with ammonium sulfate were indicated to be the best carbon and nitrogen sources, respectively. With the increase of Tween-80 from 0 to 10 g l⁻¹, the lipase production was greatly enhanced from merely 250 U l⁻¹ to a maximum of 3,340 U l⁻¹, giving the highest lipase yield of ca 640 U g⁻¹ dry cell mass (DCW), although the maximum biomass (6.0 g DCW l⁻¹) was achieved at 15 g l⁻¹ of Tween-80. When the medium loading in shake flasks was reduced from 20 to 10% (v / v), the lipase production was significantly enhanced. The increase in shaking speed also resulted in an improvement of the lipase production, although the cell growth was slightly repressed, suggesting that the increase of dissolved oxygen (DO) concentration contributed to the enhancements of lipase yield. When the lipase fermentation was carried out in a 5-l fermenter, the lipase production reached a new maximum of 11,060 U l⁻¹ by simply raising the aeration rate from 0.5 to 1.0 vvm, while keeping the dissolved oxygen above 20% saturation via intermittent adjustment of the agitation speed (≥400 rpm), in the presence of a relatively low concentration (2 g l⁻¹) of Tween-80 to prevent a potential foaming problem, which is easy to occur in the intensively aerated fermenter.     

Production of chitinolytic enzymes with Trichoderma longibrachiatum IMI 92027 in solid substrate fermentation

Thirty Trichoderma strains representing 15 species within the genus were screened for extracellular production of chitinolytic enzymes in solid substrate fermentation. Trichoderma longibrachiatum IMI 92027 (ATCC 36838) gave the highest yield (5.0 IU/g of dry matter of substrate) after 3 d of fermentation on wheat bran-crude chitin (9:1 mixture) medium. The optimal moisture content (66.7%), chitin content (20%), initial pH of the medium (2.0–5.0), and time course (5 d) of solid substrate fermentation were determined for strain IMI 92027. Cellulase, xylanase, α-amylase, and β-xylosidase activities were also detected. The pH and temperature optima of the chitinase complex of T. longibrachiatum IMI 92027 were 4.5 and 55°C, respectively. The enzyme totally lost its activity at 70°C in 5 min in the absence of the substrate but retained about 15% of its initial activity even at 70°C after a 60-min incubation in the presence of solid substrate fermentation solids. Purification of protein extract from the solid substrate fermentation material revealed high chitinolytic activities between pI 5.9 and 4.8, where N-acetyl-β-d-hexosaminidase and chitinase peaks have been found in the same pI range. Two chitinases of 43.5 and 30 kDa were purified at acidic pI.     

Adding Value to the Oil Cake as a Waste from Oil Processing Industry: Production of Lipase and Protease by <Emphasis Type="Italic">Candida utilis</Emphasis> in Solid State Fermentation

Olive oil cake is a by-product from the olive oil processing industry and can be used for the lipase and protease production by Candida utilis in solid state fermentation. Different carbon and nitrogen sources were evaluated, and the results showed that the supplementation of the substrate with maltose and starch as carbon sources and yeast extract as a nitrogen source significantly increased the lipase production. The best results were obtained with maltose, whereas rather low lipase and protease activities were found with glucose and oleic acid. Response surface methodology and a five-level–three-factor central composite rotatable design were used to evaluate the effects of the initial moisture content, inoculum size and fermentation time on both lipase and protease activity levels. A lipase activity value of ≈25 U g^-1 and a protease activity value of 110 U g^-1 were obtained under the optimized fermentation conditions. An alkaline treatment of the substrate appeared to be efficient, leading to increases of 39% and 133% in the lipase and protease production, respectively. The results showed that the olive cake could be a good source for enzyme production by solid state fermentation.     

Hydrogen production from paper sludge hydrolysate

The main objective of this study was to develop a system for the production of “renewable” hydrogen. Paper sludge is a solid industrial waste yielding mainly cellulose, which can be used, after hydrolysis, as a feedstock in anaerobic fermentation by (hyper)thermophilic organisms, such as Thermotoga elfii and Caldicellulosiruptor saccharolyticus. Tests on different medium compositions showed that both bacteria were able to produce hydrogen from paper sludge hydrolysate, but the amount of produced hydrogen and the requirement for other components differed. Hydrogen production by T. elfii strongly depended on the presence of yeast extract and salts. By contrast, C. saccharolyticus was less dependent on medium components but seemed to be inhibited by a component present in the sludge hydrolysate. Utilization of xylose was preferred over glucose by C. saccharolyticus.     

Ethanol Production from Residual Wood Chips of Cellulose Industry: Acid Pretreatment Investigation,Hemicellulosic Hydrolysate Fermentation,and Remaining Solid Fraction Fermentation by SSF Process

Current research indicates the ethanol fuel production from lignocellulosic materials, such as residual wood chips from the cellulose industry, as new emerging technology. This work aimed at evaluating the ethanol production from hemicellulose of eucalyptus chips by diluted acid pretreatment and the subsequent fermentation of the generated hydrolysate by a flocculating strain of Pichia stipitis. The remaining solid fraction generated after pretreatment was subjected to enzymatic hydrolysis, which was carried out simultaneously with glucose fermentation [saccharification and fermentation (SSF) process] using a strain of Saccharomyces cerevisiae. The acid pretreatment was evaluated using a central composite design for sulfuric acid concentration (1.0–4.0 v/v) and solid to liquid ratio (1:2–1:4, grams to milliliter) as independent variables. A maximum xylose concentration of 50 g/L was obtained in the hemicellulosic hydrolysate. The fermentation of hemicellulosic hydrolysate and the SSF process were performed in bioreactors and the final ethanol concentrations of 15.3 g/L and 28.7 g/L were obtained, respectively.     

Temperature variations and amyloglucosidase levels at different bed depths in a solid state fermentation system

Studies on moist wheat bran medium, inoculated with Aspergillus niger CFTRI 1105, indicate steep gradients in the temperature and enzyme levels at different depths in deep bed rectangular fermenters with different loads. An increase of about 2.5 °C over a bed depth of 40 mm in a fermenter with a load of 49.7 kg m⁻² was due to metabolic heat generation in the initial fermentation period. This was found to result in a doubled fermentation time to attain enzyme levels which were comparable, although still lower by 4.6%, with those in a fermenter with a load of 17.8 kg m⁻². The temperature variations were about 10–18 °C for a bed depth of 80 mm and the highest enzyme levels were lower by 23.4%, even after 48 h, with a load of 49.7 kg m⁻² compared with those for a load of 17.8 kg m⁻² . The metabolic heat and enzyme biosynthesis functions were found to be significantly affected by an increase in bed depth. The maximum temperature variations recorded in the fermenter with a load of 126.1 kg m⁻² were 19.5 °C at 12 h and 21.2 °C at 60 h for 80 and 160 mm bed depths respectively. Consequently, the maximum enzyme levels were lower by 81%–86% and required a 2.5-fold increase in fermentation time compared with a fermenter with a load of 17.8 kg m⁻².The results indicate that the temperature gradients play a key role in the biosynthesis of the enzyme in a solid state fermentation system involving deep beds.     

Optimization of Spore and Antifungal Lipopeptide Production During the Solid-state Fermentation of <Emphasis Type="Italic">Bacillus subtilis</Emphasis>

Bacillus subtilis strain TrigoCor 1448 was grown on wheat middlings in 0.5-l solid-state fermentation (SSF) bioreactors for the production of an antifungal biological control agent. Total antifungal activity was quantified using a 96-well microplate bioassay against the plant pathogen Fusarium oxysporum f. sp. melonis. The experimental design for process optimization consisted of a 2⁶⁻¹ fractional factorial design followed by a central composite face-centered design. Initial SSF parameters included in the optimization were aeration, fermentation length, pH buffering, peptone addition, nitrate addition, and incubator temperature. Central composite face-centered design parameters included incubator temperature, aeration rate, and initial moisture content (MC). Optimized fermentation conditions were determined with response surface models fitted for both spore concentration and activity of biological control product extracts. Models showed that activity measurements and spore production were most sensitive to substrate MC with highest levels of each response variable occurring at maximum moisture levels. Whereas maximum antifungal activity was seen in a limited area of the design space, spore production was fairly robust with near maximum levels occurring over a wider range of fermentation conditions. Optimization resulted in a 55% increase in inhibition and a 40% increase in spore production over nonoptimized conditions.     

Kinetic and Stoichiometric Parameters in the Production of Carotenoids by <Emphasis Type="Italic">Sporidiobolus salmonicolor</Emphasis> (CBS 2636) in Synthetic and Agroindustrial Media

With the objective of determining the kinetic behavior (growth, substrate, pH, and carotenoid production) and obtain the stoichiometric parameters of the fermentative process by Sporidiobolus salmonicolor in synthetic and agroindustrial media, fermentations were carried out in shaken flasks at 25°C, 180 rpm, and initial pH of 4.0 for 120 h in the dark, sampling every 6 h. The maximum concentrations of total carotenoids in synthetic (913 μg/L) and agroindustrial (502 μg/L) media were attained approximately 100 h after the start of the fermentative process. Carotenoid bioproduction is associated with cell growth and the ratio between carotenoid production and cell growth (Y _P/X) is 176 and 163 μg/g in the synthetic and agroindustrial media, respectively. The pH of the agroindustrial fermentation medium varied from 4.2 to 8.5 during the fermentation. The specific growth rate (μ _X) for S. salmonicolor in synthetic and agroindustrial media was 0.07 and 0.04 h⁻¹, respectively. The synthetic medium allowed for greater productivity, obtaining maximum cell productivity (P _x) of 0.08 g L⁻¹ h⁻¹ and maximum total carotenoid productivity (P _car) of 14.2 μg L⁻¹ h⁻¹. Knowledge of the kinetics of a fermentative process is of extreme importance when transposing a laboratory experiment to an industrial scale, as well as making a quantitative comparison between different culture conditions.     

Effect of Constant Glucose Feeding on the Production of Exopolysaccharides by <Emphasis Type="Italic">Tremella fuciformis</Emphasis> Spores

A fed-batch culture system with constant feeding (glucose 80 g L⁻¹, 0.25 ml min⁻¹) was used to study the influence of glucose on cell dry weight and exopolysaccharides production from submerged Tremella fuciformis spores in a 5-L stirred-tank bioreactor. The results showed that high levels of cell mass (9.80 g L⁻¹) and exopolysaccharides production (3.12 g L⁻¹) in fed-batch fermentation were obtained after 1 h of feeding, where the specific growth rate (μ) and exopolysaccharides yield on substrate consumed (YP/S) were 0.267 d⁻¹ and 0.14 g g⁻¹. Unlike batch fermentation, maximal cell mass and exopolysaccharides production merely reached 7.11 and 2.08 g L⁻¹; the specific growth rate (μ) and exopolysaccharides yield on substrate consumed (YP/S) were 0.194 d⁻¹ and 0.093 g g⁻¹, respectively. It is concluded that the synthesis of exopolysaccharides can be promoted effectively when feeding glucose at a late exponential phase.     

Thermal analysis of the system triamterene-d-mannitol

Thermal analysis (DSC and HSM), and equilibrium solubility determinations were carried out to elucidate the mechanism of interaction at the solid state in the binary system triamterene-D-mannitol. Physical mixtures (5–90% w/w triamterene) and solid dispersions (5 up to 40% w/w triamterene) were prepared and studied. From DSC and HSM results, the thermal changes were associated with the variations in composition of the binary mixture, being more pronounced in the range 20–50% w/w. The binary phase diagram was proposed, although the exact position of the eutectic was uncertain. This is in accordance with a partial dissolution process detected by HSM. A linear increase in the solubility of triamterene with increasing aqueous mannitol concentration was obtained. The thermodynamic parameters of the solution properties were calculated, with an activation energy value of 96.081 kJ/mole. The solubilization increase was associated with complexation processes and hydrogen bonding formation. Dedicated to Professor Lisa Heller-Kallai on the occasion of her 65^th birthday     

Production of Cordycepin and Mycelia by Submerged Fermentation of Cordyceps militaris in Mixture Natural Culture

The submerged fermentation of Cordyceps militaris for cordycepin production and mycelial growth was investigated in this study. Three natural materials of brown rice paste (BRP), beerwort (B), and soybean meal juice (SMJ) were used for fermentation of C. militaris in shaking flasks. The effects of the ratio of three natural materials on dry mycelium weight (DMW) and on cordycepin yield (CY) were analyzed. D-Optional mixture design was used to optimize the ratio of these materials. Compared with the signal culture, the higher mycelial growth and cordycepin production were obtained in mixture. The analysis of Design Expert 6.0 indicated that BRP, B, and SMJ very significantly influenced (P < 0.001) DMW and CY of C. militaris, respectively. The highest DMW (18.96 g/l) and CY (2.17 mg/g) were both obtained at a ratio of 53:6:42. The experiments’ results indicated that the above mixture of these natural materials by D-optional mixture design can be used as a proper medium for the growth of mycelium and the production of cordycepin.